Kollmorgen Automation Suite(TM) Delivers Dynamic Performance to Maximize Productivity of Fully Automated Modular Paper Processing Machine

Jumbo roll collator, manufactured by German-based Jakob Graphic Services GmbH, raises the bar when it comes to processing a wide variety of printed continuous paper products.

RADFORD, VA - The jumbo roll collator from Jakob Graphic Services GmbH can automatically collate, glue, label, fold and cut forms, mailers with cut inserts, brochures with or without a finish, calendars and similar printed matter. These machines deliver precise operation during highly-dynamic processes while quickly adapting to new tasks with an extremely simple and fast changeover system. In fact, servo cutter format adjustments, and even extensive changes, can be carried out in just seconds. At the heart of this machine is Kollmorgen Automation Suite(TM) (KAS). In addition to powerful Kollmorgen servo technology, the KAS software package plays a vital role in speeding development and commissioning with simplified programming interface and real-time system simulation.

Key Achievements with Kollmorgen Automation Suite (KAS) include:
  • Cabinet size reduction with all-in-one IPC module
  • Total application development time: 1 week
  • Machine throughput: 200m/min* (+30%)
    *Actual cutting speed varies based on type of cut

    Most customers have a comprehensive range of printed paper products, and changeover and set-up times significantly reduce machine efficiency. With that in mind, Jakob Graphic Services wanted to develop a machine that not only provided high-level functionality with sound construction, but that delivered simplified operation with rapid machine retooling. They quickly determined that cutting-edge servo technology would deliver the performance and functionality the company needed to make this a truly groundbreaking automated paper collating machine, and they partnered with Kollmorgen to provide the solution.

    High-level Flexibility is a Must for the Jakob Roll Collator
    This advanced solution enables users to produce continuous form sheets, individual sheets and mailing products more quickly and efficiently than ever before. The maximum roll diameter is 50", and the roll width can range from 100 to 500 mm (4 in. - 27 in.). The collated webs can be crimped, glued or stitched. Crimping tools connect the webs. After cross cutting, accelerator belts are used to guide the streams to a shingle conveyor. Once a specified number of streams have been reached, the streams are automatically stacked for packaging.

    Unlike traditional machines, it eliminates the need to change the cylinders and gearwheels used for cross cutting or perforating various paper formats thanks to the use of Kollmorgen high performance AKM(TM) servomotors and precision gear boxes.

    Customized formats are ready for use in the freely programmable control unit. Format changeover is executed at the touch-screen display. Additional technical features include:
  • Electronic row gluing valves that enable gluing applications at high switching frequencies
  • Various slitting units for cutting off sprocket hole strips
  • Ability to integrate additional equipment such as pre-sorters, labelers, laser / ink-jet systems, and additional printing / pocket folding units

    Retooling Times at the Servo Cutter Offer Room for Improvement
    The developers at Jakob Graphic Services GmbH are convinced that the lynchpin of machine development, the primary design challenge, was to ensure that the cylinder - irrespective of the printing format - would allow for variable cut-off formats of the supplied printed continuous paper webs, along with easily executable adjustments. Even between individual sections it had to be possible to carry out further adjustments to handle challenges like asymmetric formats during processing.

    As an example, this functionality would ensure that the size of a 378 mm format calendar block would be increased by 50 mm during continuous printing so that a common inch format could be applied in the process. Although the servo cutter cylinder would be set to 24 in., it would need to be electronically reprogrammed to 17 in. to ensure the said 50 mm would be cut off. Adjustments between the blades or cuts always result in acceleration or deceleration. However, the separating cuts always occur in synchronization with the paper web speed to maximize productivity for the system operator. The Kollmorgen Automation Suite satisfies these needs, while providing Jakob Graphic Services the software and hardware support for not just existing, but future applications as well.

    "The crucial factor for the decision to go with the Kollmorgen Automation Suite was that the Motion Control, PLC and HMI/SCADA functionalities - in our case on an industrial PC - are available via a single processor. This standard tool allows the cost-effective introduction of company-specific knowhow and tailored solutions for individual applications," explains the Design Engineering and Technical Manager at Jakob Graphic Services GmbH. "Furthermore, it radically speeds up programming and commissioning, and increases machine performance."

    Kollmorgen Automation Suite - Scalable System with Standardized Development Environment
    Kollmorgen Automation Suite is rooted in the company's proven, highly intuitive Pipe Network(TM) programming language. It is a scalable system with a standardized development platform that directly links all three main functions of a control system - HMI, PLC and Motion Control - in a common development and software environment. The integrated development tools include a complete set of IEC 61131-3 language editors,(Sequential Function Chart - SFC, Function Block Diagram - FDB, Ladder Diagram - LD, Structured Text - ST and Instruction List - IL), a common program compiler, an offline Motion PLC program simulator, and a HMI development tool. This all-in-one solution considerably reduces programming and commissioning time.

    The extensive KAS functions allow the machine developer to quickly assemble the program and achieve the performance output in a system-supported visual project engineering environment. Programming in KAS is simply describing the mechanical relationships between components with the aid of graphical description blocks. An extensive motion library is available for the graphical PipeNetwork editor to complete this task. All the machine's internal processes, no matter how complex, can be simulated to determine the optimum settings and eliminate problems prior to commissioning, with the results loaded directly into the control system.

    "With KAS we've found an ideal servo-technical solution for our existing and future processing machines, ensuring they satisfy the high performance demands of our customers. The resulting technical characteristics are significant for Jakob machines, and create a unique selling point. Time-consuming manual retooling or set-up measures are a thing of the past thanks to the electronic servo technology. The time saved with this new procedure has proven to be very profitable. Setbacks caused by errors are excluded, and commissioning has become a 'formal procedure'," says Sales Manager at Jakob Graphic Services GmbH. "Moreover, it is highly beneficial to have an 'everything from one source' partner - from fully digital servo amplifiers, servo motors, Motion Control, PLC to visualization (HMI) and touch-screen display."

    Since 1985 Jakob Graphic Services GmbH has been designing machinery and units for processing of printed products. The patented ROTALOCK fastening head served as the foundation of the company's product range, and today Jakob pile and reel collators are running single and multiple shifts in a great number of printing shops around the world.

    Machinery systems for producing calendar blocks, and off-line solutions using servo-cutter and servo-folder functionality, round out the wide spectrum of available solutions. Jakob is adept at partnering with its customers to help guarantee the exact realization of their specific application needs.

    For more information visit www.jakob-gmbh.eu/content/index_eng.html or call 0049 6157 95170.

    Kollmorgen is a leading provider of motion systems and components for machine builders around the globe, with over 60 years of motion control design and application expertise.

    Through world-class knowledge in motion, industry-leading quality and deep expertise in linking and integrating standard and custom products, Kollmorgen delivers breakthrough solutions unmatched in performance, reliability and ease-of-use, giving machine builders an irrefutable marketplace advantage.

    For more information visit www.kollmorgen.com, email contactus@kollmorgen.com or call 1-540-633-3545.

    More from Mechanical Power Transmission

  • All Topics